A waste ceramic mold gypsum recycling system

Abstract

The embodiment of the application provides a kind of waste ceramic mould gypsum recycling system, it is related to solid waste gypsum recycling technical field.A kind of waste ceramic mould gypsum recycling system, including crusher one, conveyor one, crystal converter, elevator one, semi-finished product bin, mill, elevator two and finished product bin, crusher one is used to break the gypsum in waste ceramic mould to particle size less than 15cm, the gypsum after crushing is conveyed to crystal converter in conveyor one, by solution delivery pump, the crystal modifier solution in additive solution pool is conveyed to crystal converter, and the crystal modifier solution is soaked in the waste mould gypsum in crystal converter.The utility model is through crushing, crystal conversion, drying and grinding etc.Process, waste ceramic mould gypsum is efficiently converted into the performance excellent regenerated gypsum, not only realizes resource recycling, reduces production cost and energy consumption, also significantly reduces environmental pollution, with good economic, environmental protection benefit and extensive industrial application prospect.

Description

Technical Field

[0001] This application relates to the field of solid waste gypsum recycling technology, and more specifically, to a waste ceramic mold gypsum recycling system. Background Technology

[0002] my country is a major global producer of ceramics, particularly in daily-use ceramics, sanitary ceramics, and art ceramics. The production of these ceramic products requires a large amount of plaster powder for mold making. However, as molds are used more frequently, they gradually age and eventually become obsolete. Statistics show that my country generates approximately 2.5 million tons of waste ceramic mold plaster annually.

[0003] Currently, the main use of waste ceramic molds is as a cement retarder, or they are directly calcined after simple washing and crushing. Because waste mold gypsum is a secondary dihydrate gypsum with fine crystals and a large specific surface area, quality control during calcination is difficult. This results in gypsum powder with problems such as high consistency (usually above 85%) and low strength (flexural strength less than 1.6 MPa after 2 hours), failing to meet the application requirements of mold gypsum powder. Therefore, the common practice is to add 10-25% waste mold gypsum powder to natural gypsum mold powder. However, due to the limited addition ratio, the utilization rate of waste molds is low, the cost-effectiveness is not high, and improper addition can affect the application effect.

[0004] Furthermore, ceramic production bases generate a large amount of unused waste mold plaster, which is seriously piling up, while ceramic enterprises still need to purchase large quantities of natural mold plaster powder from external sources. Producing natural mold plaster powder requires high-quality ore, but the cost of natural plaster resources is high due to environmental protection, safety, and geographical factors. In contrast, waste mold plaster has advantages such as high purity and whiteness, making it a high-quality raw material. However, because it is a secondary dihydrate gypsum, it cannot be adapted to conventional plaster production processes, resulting in its ineffective application.

[0005] This utility model patent proposes a waste ceramic mold plaster recycling system. Through a crystal transformation technology and proper integration with waste mold plaster, secondary fine dihydrate plaster crystals are converted into larger crystals, thereby improving product strength, reducing standard consistency, and adjusting setting time, ultimately producing products that meet mold plaster powder standards. This method not only achieves effective recycling of waste mold plaster but also solves problems existing in current processing methods, reduces dependence on natural plaster resources, and increases the added value and market competitiveness of waste mold plaster. Utility Model Content

[0006] To achieve the above objectives, this utility model provides a waste ceramic mold gypsum recycling system, including a crusher, a conveyor, a crystallizer, an elevator, a semi-finished product silo, a mill, an elevator 2, and a finished product silo. The crusher is used to crush the gypsum in the waste ceramic mold to a particle size of less than 15cm. The crushed gypsum is conveyed to the crystallizer by the conveyor. A crystallizer solution from an additive solution tank is conveyed to the crystallizer by a solution transfer pump. The crystallizer solution permeates the waste mold gypsum in the crystallizer. After soaking, open the outlet of the crystallizer solution at the bottom of the crystallizer to release all the crystallizer solution into the additive solution pool for recycling. Then, steam is introduced into the crystallizer cavity and drying pipeline for crystallization. After the crystallization is completed, the steam in the cavity is discharged and the waste mold gypsum is dried by the drying system to obtain hemihydrate gypsum. After the hemihydrate gypsum enters the storage hopper, it is transported to the semi-finished product warehouse by conveyor two and elevator one for storage. The mill grinds the hemihydrate gypsum in the semi-finished product warehouse to obtain the finished product. The leveling gypsum is transported to the finished product warehouse for storage by elevator two.

[0007] Furthermore, the crystal converter includes a vessel body with an upper end cap at the top and a drying pipeline inside the vessel body. The upper part of the vessel body has a crystal-converting agent solution inlet and a crystal-converting steam inlet. The outside of the vessel body has a drying pipeline steam inlet connected to the upper part of the drying pipeline and a drying pipeline condensate outlet connected to the lower part of the drying pipeline. The lower part of the vessel body has a crystal converter lower end cap, with a filter plate inside the lower end cap. The bottom of the lower end cap has a crystal-converting condensate outlet and a crystal-converting agent solution outlet.

[0008] Furthermore, the drying system includes simultaneously introducing saturated steam into the crystal converter and the drying pipeline and maintaining pressure. After the crystal conversion is completed, the steam supply to the crystal converter is stopped and the steam in the crystal converter is discharged. Steam is introduced into the drying pipeline and the pressure is increased and maintained to dry the hemihydrate gypsum in the crystal converter to obtain hemihydrate gypsum.

[0009] Furthermore, the drying system also includes maintaining pressure in the reactor body and drying pipeline network, stopping the supply of steam to the reactor body and drying pipeline network after the crystallization is completed, discharging the steam in the reactor body, opening the lower end cap, unloading the hemihydrate gypsum containing attached water, transporting it to the stockpile for natural drying, crushing the dried gypsum through crusher two, and then transporting the gypsum to the dryer for drying by conveyor three.

[0010] Furthermore, the crystallization agent solution is one or more of inorganic salts, organic acids, and organic acid salts, and is prepared at a concentration of 0.05-0.5%.

[0011] Furthermore, the dryer 64 is an indirect heat exchange dryer.

[0012] The beneficial effects of this application are as follows: Through processes such as crushing, crystallization treatment, drying, and grinding, waste ceramic mold gypsum is transformed into high-quality recycled gypsum products, significantly improving resource utilization and reducing waste accumulation and environmental pollution. The use of crystallization agent solution treatment and steam crystallization technology transforms secondary, fine dihydrate gypsum crystals into larger, more regular, short columnar crystal structures, significantly improving product strength while reducing standard consistency and adjusting setting time. This allows the recycled gypsum to meet the application requirements of β-type ceramic mold gypsum powder. Since the recycled gypsum can be directly used in ceramic mold production without the addition of natural gypsum, it not only saves on the cost of purchasing natural gypsum but also reduces dependence on high-quality natural gypsum ore, further lowering raw material procurement costs. Furthermore, the recycled gypsum production process is relatively simple. This process boasts low energy consumption, particularly through optimized crystallization technology and drying methods, which reduces energy consumption during production and consequently lowers overall production costs. Furthermore, it minimizes the environmental pollution risks posed by waste ceramic mold plaster, avoiding the land-use constraints of large-scale waste dumping. The crystallization agent solution used in production can be recycled, reducing chemical waste and emissions, aligning with the principles of green and sustainable development. Moreover, this process is applicable to waste ceramic mold plaster of various specifications and shapes, demonstrating strong adaptability. Whether using integrated or separate drying methods, it ensures the stability and consistency of the final product's quality. By flexibly adjusting parameters such as the type and concentration of the crystallization agent, steam pressure, and holding time, the process can be optimized to meet specific needs and ensure optimal product performance.

[0013] Additional aspects and advantages of this application will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of this application. Attached Figure Description

[0014] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments of this application will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0015] Figure 1 This is a schematic diagram of the integrated crystal conversion and drying process according to an embodiment of this application;

[0016] Figure 2 This is a schematic diagram of crystallization drying and separation according to an embodiment of this application;

[0017] Figure 3 This is a schematic diagram of a crystal converter according to an embodiment of this application;

[0018] Figure 4This is a flowchart of the integrated crystal conversion and drying process according to an embodiment of this application;

[0019] Figure 5 This is a flowchart of the crystallization drying and separation process according to an embodiment of this application;

[0020] icon:

[0021] 10. Crusher 1; 20. Conveyor 1; 30. Solution transfer pump; 40. Additive solution tank; 50. Crystal converter; 51. Upper head; 52. Kettle body; 53. Drying pipeline network; 54. Lower head; 55. Crystal converter solution inlet; 56. Crystal converter steam inlet; 57. Crystal converter condensate outlet; 58. Crystal converter solution discharge outlet; 59. Filter plate; 510. Drying pipeline network steam inlet; 511. Drying pipeline network condensate outlet; 60. Storage hopper; 61. Conveyor 2; 62. Crusher 2; 63. Conveyor 3; 64. Dryer; 70. Elevator 1; 71. Semi-finished product silo; 72. Mill; 73. Elevator 2; 74. Finished product silo. Detailed Implementation

[0022] The technical solutions in the embodiments of this application will now be described with reference to the accompanying drawings.

[0023] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, not all of them. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0024] Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of the application. All other embodiments obtained by those skilled in the art based on the embodiments in this application without inventive effort are within the scope of protection of this application.

[0025] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0026] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the equipment or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0027] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0028] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "joining," "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0029] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature being directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0030] The following describes a waste ceramic mold plaster recycling system according to an embodiment of this application, with reference to the accompanying drawings.

[0031] Example 1

[0032] like Figure 1 , Figure 3 and Figure 4As shown, an embodiment of this application discloses a waste ceramic mold gypsum recycling system, which efficiently converts gypsum from waste ceramic molds into high-performance β-type ceramic mold hemihydrate gypsum powder, thereby achieving green recycling of resources. The system includes a crusher 10, a conveyor 20, a crystallizer 50, an elevator 70, a semi-finished product silo 71, a mill 72, an elevator 2 73, and a finished product silo 74. It is also equipped with auxiliary equipment such as an additive solution tank 40, a solution transfer pump 30, a storage hopper 60, a conveyor 2 61, and a dryer 64.

[0033] Crusher 10 is used to initially crush the gypsum raw material in the waste ceramic mold to make its particle size less than 15cm, so as to meet the particle size requirements of the subsequent crystallization process. The crushed gypsum particles are conveyed to the special crystallizer 50 by conveyor 20 for crystal structure modification treatment.

[0034] The crystal converter 50 is the core processing unit of this system. It includes a vessel body 52, an upper head 51, a lower head 54, and a drying pipe network 53 located inside the vessel body. The vessel body 52 has a steam inlet 510 connected to the upper part of the drying pipe network 53 and a condensate outlet 511 connected to the lower part of the drying pipe network 53. The upper part of the vessel body 52 has a crystal-changing agent solution inlet 55 and a crystal-changing steam inlet 56. The upper head 51 serves as a feed inlet connected to the end of the conveyor 20. The lower head 54 is detachably installed at the bottom of the vessel body 52 for easy discharge and maintenance. The bottom of the lower head 54 has a crystal-changing condensate outlet 57 and a crystal-changing agent solution outlet 58. The lower head 54 has a filter plate 59 inside to filter the liquid generated during the crystal-changing process and prevent the loss of gypsum particles.

[0035] In the operation process of the crystal converter 50, the prepared crystal conversion agent solution is first transported from the additive solution tank 40 to the crystal conversion agent solution inlet 55 at the top of the crystal converter body 52 by the solution transfer pump 30, so that the crystal conversion agent solution can evenly penetrate the waste mold gypsum loaded into the body. The crystal conversion agent solution is prepared from one or more of the following: inorganic salts such as aluminum sulfate, potassium sulfate, potassium aluminum sulfate, organic acids such as citric acid, tartaric acid, succinic acid, or organic acid salts such as sodium citrate, sodium succinate. The concentration is controlled within the range of 0.05% to 0.5%, and the soaking time is set to 0.5 to 3 hours to ensure that the gypsum crystals react fully.

[0036] After soaking, open the crystallization agent solution outlet 58 at the bottom of the lower end cap 54 to discharge the used crystallization agent solution and recycle it to the admixture solution pool 40, thereby reducing chemical consumption and wastewater discharge.

[0037] Saturated steam is then introduced into the vessel 52 of the crystallizer 50, while steam is supplied to the drying pipeline 53. The steam pressure is controlled at 0.15-0.4 MPa, and the pressure holding time is 4-8 hours. Under these conditions, the waste mold gypsum undergoes a dehydration and crystallization reaction to form hemihydrate gypsum with a short columnar crystal structure and an attached water content of 15%-20%.

[0038] After the crystallization is completed, the steam supply to the reactor body 52 is stopped and the internal steam is discharged, leaving only the steam supply to the drying pipeline 53. At this time, the steam pressure is gradually increased to 0.5-0.65 MPa and the pressure holding time is extended to 12-16 hours to deeply dry the hemihydrate gypsum, and finally a qualified hemihydrate gypsum product with a crystal water content of 4.5%-6.5% is obtained.

[0039] After drying, the hemihydrate gypsum is first temporarily stored in the storage hopper 60, and then conveyed to the semi-finished product silo 71 by the first elevator 70. After that, it enters the mill 72 for grinding, with the fineness controlled between 100 and 200 mesh. The ground finished gypsum is then conveyed to the finished product silo 74 by the second elevator 73 for storage, in preparation for subsequent use in the production of ceramic molds.

[0040] Example 2

[0041] like Figure 2 and Figure 5 As shown, in another embodiment of this utility model, a separate drying process is used to further dry the hemihydrate gypsum after crystallization. The specific operation process is as follows:

[0042] After the waste mold gypsum in the crystallizer 50 completes the crystallization reaction, saturated steam is introduced into the reactor body 52 and the internal drying pipeline 53, and the pressure is maintained at 0.15–0.4 MPa for 4–8 hours to allow the material to complete the crystal structure transformation from dihydrate gypsum to hemihydrate gypsum. At this time, the hemihydrate gypsum contains a certain amount of attached water, with a content of 15%–30%.

[0043] Subsequently, steam supply to the reactor body 52 and drying pipeline 53 is stopped, and the remaining steam inside the reactor body 52 is discharged. After the system pressure is released, the lower end cap 54 of the crystallizer is opened to unload the hemihydrate gypsum containing attached water, and it is transported to the stockpile for natural drying. During the drying process, the attached water content can be reduced to below 5% to meet the requirements of subsequent mechanical crushing and drying.

[0044] After drying, the hemihydrate gypsum enters crusher 2 (62) for crushing, controlling the particle size to less than 15mm to improve subsequent drying efficiency and ensure material flowability. The crushed gypsum particles are then conveyed by conveyor 3 (63) to a dedicated drying equipment for deep drying.

[0045] Dryer 64 employs an indirect heat exchange dryer, transferring heat through a layer of external heating medium such as steam or heat transfer oil in contact with the material, avoiding direct contact between the material and the heat source that could cause contamination or performance degradation. In this equipment, gypsum is heated to an outlet temperature of 140–170°C, stabilizing the crystal water content between 4.5% and 6.5%, meeting the technical requirements for β-type hemihydrate gypsum used in ceramic molds. The dried hemihydrate gypsum is then transported by elevator 70 to a semi-finished product silo 71 for storage. It then enters mill 72 for grinding, with the fineness controlled between 100 and 200 mesh. The ground finished gypsum is then transported by elevator 73 to a finished product silo 74 for storage, ready for subsequent use in ceramic mold production.

[0046] The above are merely embodiments of this application and are not intended to limit the scope of protection of this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of protection of this application. It should be noted that similar reference numerals and letters in the following figures indicate similar items; therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0047] The above are merely specific embodiments of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A waste ceramic mold plaster recycling system, characterized in that, The system includes a crusher (10), a conveyor (20), a crystal converter (50), an elevator (70), a semi-finished product silo (71), a mill (72), an elevator (73), and a finished product silo (74). The crusher (10) is used to crush the gypsum in the waste ceramic mold to a particle size of less than 15cm. The crushed gypsum is conveyed to the crystal converter (50) by the conveyor (20). The crystal converter solution in the admixture solution tank (40) is conveyed to the crystal converter (50) by the solution transfer pump (30). The crystal converter solution permeates the waste mold gypsum in the crystal converter (50). After soaking, the bottom of the crystal converter (50) is opened. The crystallizer solution outlet (58) discharges all the crystallizer solution into the additive solution pool (40) for recycling. Then, steam is introduced into the crystallizer (50) cavity and the drying pipeline (53) for crystallization. After the crystallization is completed, the steam in the cavity is discharged and the waste mold gypsum is dried by the drying system to obtain hemihydrate gypsum. After the hemihydrate gypsum enters the storage hopper (60), it is transported to the semi-finished product warehouse (71) by the second conveyor (61) and the first elevator (70) for storage. The mill (72) grinds the hemihydrate gypsum in the semi-finished product warehouse (71) to obtain the finished product. The flat gypsum is transported to the finished product warehouse (74) by the second elevator (73) for storage.

2. The waste ceramic mold plaster recycling system according to claim 1, characterized in that: The crystal converter (50) includes a vessel body (52), an upper end cap (51) at the upper end of the vessel body (52), a drying pipeline (53) inside the vessel body (52), a crystal conversion agent solution inlet (55) and a crystal conversion steam inlet (56) at the upper part of the vessel body (52), a drying pipeline steam inlet (510) connected to the upper part of the drying pipeline (53) and a drying pipeline condensate outlet (511) connected to the lower part of the drying pipeline (53) outside the vessel body (52), a crystal converter lower end cap (54) at the lower part of the vessel body (52), a water filter plate (59) inside the lower end cap (54), and a crystal conversion condensate outlet (57) and a crystal conversion agent solution outlet (58) at the bottom of the lower end cap (54).

3. The waste ceramic mold plaster recycling system according to claim 1, characterized in that: The drying system includes simultaneously introducing saturated steam into the crystal converter (50) and the drying pipeline (53) and maintaining pressure. After the crystal conversion is completed, the steam supply to the crystal converter (50) is stopped and the steam in the crystal converter (50) is discharged. Steam is introduced into the drying pipeline (53) and the pressure is increased and maintained to dry the hemihydrate gypsum in the crystal converter (50) to obtain hemihydrate gypsum.

4. The waste ceramic mold plaster recycling system according to claim 3, characterized in that: The drying system also includes maintaining pressure in the reactor body (52) and the drying pipeline (53). After the crystallization is completed, the steam supply to the reactor body (52) and the drying pipeline (53) is stopped, and the steam in the reactor body (52) is discharged. The lower end cap (54) is opened, and the hemihydrate gypsum containing attached water is unloaded and transported to the stockpile for natural drying. The dried gypsum is crushed by the second crusher (62), and the gypsum is transported to the dryer (64) by the third conveyor (63) for drying.

5. The waste ceramic mold plaster recycling system according to claim 4, characterized in that: The dryer (64) is an indirect heat exchange dryer.

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